Opex Perfect Pick User manual

© 2015 OPEX®Corporation
All rights reserved. This publication is made available solely for use by the OPEX Service Organization. The infor-
mation contained herein is proprietary, confidential and copyrighted by OPEX®Corporation. Copying, duplicating,
selling, or otherwise distributing any part of this publication or the information contained herein without the express
written consent of OPEX®Corporation is strictly forbidden.
July 15, 2015
Document Revision 15-01
Perfect Pick User Manual

2
Perfect Pick User Manual - OPEX Corporation use only - not for distribution
Document History
If you find errors, inaccuracies, or any other issues or concerns with this
document, please contact the OPEX Technical Writers via email at:
[email protected]
Doc
Rev Date Changes (click blue text to go to that page)
13-01 May 2013 Initial Release.
15-01 July 15, 2015
Page 22 - Updated Diagnostic screen (Fig. 7)
Page 26 - Added FCC rules and regulations as well as
Industry Canada Information
Page 2 - New Document History table implemented

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Perfect Pick User Manual - OPEX Corporation use only - not for distribution
Table of Contents
Document History ................................................................................................ 2
Table of Contents ................................................................................................ 3
Chapter 1
Introduction
About this manual ................................................................................................ 6
Terminology .................................................................................................... 6
Overview .............................................................................................................. 8
The Perfect Pick™ Solution ............................................................................ 8
Base System ................................................................................................... 9
Safety ................................................................................................................ 10
Other Cautions .............................................................................................. 13
Ultra-capacitor Product Information ................................................................... 14
Interlock system ................................................................................................. 15
Emergency Stop (E-Stop) switches .............................................................. 16
Light Tower ................................................................................................... 17
Using Perfect Pick ............................................................................................. 18
Inventory Control System software ............................................................... 18
OPEX software .................................................................................................. 22
Specifications .................................................................................................... 23
Physical Specifications: ................................................................................ 23
Tote/Tray Specifications: .............................................................................. 23
iBOT Specifications: ...................................................................................... 25
Environmental Specifications: ....................................................................... 25
Wireless Transceiver ......................................................................................... 26
FCC information / informations FCC ............................................................. 26
Industry Canada information / Industrie Canada l'information ...................... 27

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Perfect Pick User Manual - OPEX Corporation use only - not for distribution

User Manual
Perfect Pick
1
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ultra-capacitor Product Information . . . . . . . . . . . . . . . 14
Interlock system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Using Perfect Pick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPEX software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Introduction

6 Introduction
Perfect Pick User Manual - OPEX Corporation
About this manual
The Perfect Pick manuals use the following conventions to describe certain
procedures and situations. Please be aware of these conventions when
reading the manuals and operating the machine:
Terminology
The following terms/concepts are used to describe the software and function-
ality of the Perfect Pick machine.
Warehouse Management System (WMS)
Manages physical inventory locations, and provides automation:
conveyors, Automated Storage/Retrieval System (AS/RS), picking,
restocking, etc.
Warehouse Control System
Controls and tracks inventory movements.
Inventory Control System (ICS)
This term is used to describe the third-party software that provides both the
Warehouse Management System and the Warehouse Control System.
DANGER: Indicates a hazardous situation that, if not avoided, will result in
death or severe injury. The use of this signal word is limited to the most
extreme situations.
WARNING: Indicates a hazardous situation that, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION: Indicates a hazardous situation that, if not avoided, could result
in minor or moderate injury.
NOTICE: Indicates information considered important, but not hazard-
related.

Introduction 7
Perfect Pick User Manual - OPEX Corporation
iBOT
Tote
Storage
locations
(both sides of
the machine)
Pick station
Inventory
Control System
Monitor

8 Introduction
Perfect Pick User Manual - OPEX Corporation
Overview
The Perfect Pick™ Solution
Opex Perfect Pick™ is a fast, compact and highly scalable automated aisle
storage and piece picking solution. Ultra-capacitor powered wireless iBOTs™
(Intelligent Robotic Wireless Vehicles) navigate along a track system
integrated within the storage rack. Every iBOT can access every location and
deliver trays or totes directly to pick stations at either end of the aisle. Aisle
throughputs are highly scalable up to 1000 dual cycles per hour.
Perfect Pick is a unique, automated, goods-to-man, picking solution that
achieves superior throughput in a self-contained aisle that relies on a single
component – the iBOT.
• Perfect Pick employs proven iBOT delivery technology to pick and stock
inventory simultaneously.
• Every iBOT has access to 100% of the inventory.
• iBOTs deliver totes or trays with precise sequencing directly to ergonomi-
cally designed pick stations located at one or both ends of the aisle at rates
up to 1000 dual cycles per hour.
• As ultra-capacitor powered iBOTs navigate along a track system integrated
within the storage rack, they capture regenerated energy.
• iBOTs operate on the principle of redundancy, so Perfect Pick has no single
point of failure.
• The iBOTs can be tilted for ergonomic picking.
WARNING: Read “Safety” on page 10 before attempting to operate this
equipment.

Introduction 9
Perfect Pick User Manual - OPEX Corporation
Base System
The Perfect Pick base system includes:
• Front pick station
• Host PC with Inventory Control System software
• OPEX PC with OPEX software
• Two Storage columns (the number of tote locations varies with height and
load size).
• 5 iBOTs
The Perfect Pick can be expanded over time by adding racking modules and/or
additional iBOTs.
Note: See “Specifications” on page 23 for configuration details.

10 Introduction
Perfect Pick User Manual - OPEX Corporation
Safety
Follow these safety precautions to avoid injury when operating the Perfect
Pick. Failure to follow these precautions may result in severe personal injury or
damage to the machine.
Machine Entry Do not go inside the Perfect Pick rack system for any reason.
Only approved OPEX technicians can enter the machine.
The following label is found on both sides of the pick station(s).
Charging rail Hands should be kept clear of the charging rails at all times.
Shorting of the charging rails with either a watch or ring may result in electrical
shock.
TIP: One of the easiest ways to determine the front of the machine is to note
the location of the vertical charge rail. The vertical charge rail will always be in
the front of the machine.
Maquinaria
automatizada
NO ENTRE
Automated
machinery
CUIDADOCAUTION
DO NOT ENTER
Vertical
charge rail
Horizontal
charge rail

Introduction 11
Perfect Pick User Manual - OPEX Corporation
Climbing the structure Do not use the scissor lift, fork lifts, ladders, or climb
the structure. Only approved OPEX technicians and qualified personnel are
authorized to use the scissor lifts and iBOT recovery tools.
Moving parts Keep loose objects away from any exposed, moving parts of
the machine. The moving parts of the Perfect Pick can become jammed and/or
damaged by foreign objects. Also, keep hands, hair, loose clothing or jewelry
away from the moving parts.
Structure
Scissor lift
NO SE TREPE
A LA
ESTRUCTURA
DO NOT CLIMB
STRUCTURE
CUIDADO
CAUTION
This label is found on the exposed ends of every other
ladder, just above where the exterior cover ends. If the
machine has no rear pick station, another set of these
labels goes on the backs of the rear ladders.
MANTENGA
LAS MANOS
ALEJADAS
KEEP HANDS
AWAY
CUIDADOCAUTION
This label can be found on both
sides of each pick station, on
the metal plate above the
diagonal track.

12 Introduction
Perfect Pick User Manual - OPEX Corporation
Main Power Enclosure Only approved OPEX technicians and qualified
personnel are authorized to access the main power enclosure for trouble-
shooting and/or servicing the machine.
Main Power Enclosure
This warning label is found on the
front of the Main Power Enclosure
WARNING
ADVERTENCIA
Arc Flash and
Shock Hazard
Follow all requirements in NFPA 70E
for safe work practices and for
personal protective equipment
Riesgo de descarga
y arco eléctrico
Siga todos los requisitos
en NFPA 70E para prácticas
de trabajo seguras y equipos
de protección personal

Introduction 13
Perfect Pick User Manual - OPEX Corporation
iBOT safety The iBOT was designed to carry loads of up to 60 pounds. In
order to function properly, the iBOT incorporates automated machinery along
with potentially hazardous voltages. Therefore, it should be treated with care.
Other Cautions
Voltaje Peligrosa
Adentro
De esta Caja
Hazardous
Voltage
Inside
ADVERTENCIA
WARNING
This label is found on the exposed metal
on the top of the iBOT. One facing front,
one facing back.
MANTENGASE
ALEJADO
partes móviles
KEEP AWAY
moving parts
CUIDADOCAUTION
There are two of these labels on the iBOT,
next to the hazardous voltage labels.
Maquinaria
automatizada
Automated
machinery
CUIDADOCAUTION
This label is on the iBOT's cover. One
on each side, on the slanted surface.
CAUTION
CAUTION: The ultra-capacitors that power the iBOTs contain acetonitrile. In
the event that an ultra-capacitor should leak, avoid contact with or breathing
the acetonitrile. For information on ultra-capacitor safety, refer to “Ultra-
capacitor Product Information” on page 14.

14 Introduction
Perfect Pick User Manual - OPEX Corporation
Ultra-capacitor Product Information
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Document #1004596.4
Product Information Sheet
An MSDS is not required. This information sheet is provided as a service to our customers. An MSDS for the active chemical inside the listed products is
available upon request. For US Customers: The products referenced herein are exempt articles and are not subject to the OSHA Hazard
Communications Standard Requirement 29 CFR 1910.1200. For EU Customers: The products referenced herein are not submitted to 91-155 EEC, as
they are considered as components and not as a chemical substance. Notice: The information and recommendations herein contained are made in good
faith and are believed to be accurate at the date of preparation. Maxwell Technologies Inc. makes no warranty expressed or implied.
Product Information
Manufacturer
Maxwell Technologies Inc.
9244 Balboa Avenue San Diego, CA 92123
Phone: [phone]
Fax: [phone]
EMERGENCY PHONE:
North America
Chemtrec Hazmat Communication Center 1 800 424 9300
+ 1 703 527 3887
Europe
Swiss Toxicological Information Centre [phone]
Product: Ultracapacitors
Models: All configurations and versions of
PC5, PC10, PC5-5, BCAP0005 and
BCAP0010
Date: June 19, 2009
Asia
Chemtrec Hazmat Communication Center 1 800 424 9300
+ 1 703 527 3887
Product Components
Important Safety Note: Ultracapacitors should not be opened, disassembled, crushed, burned, or exposed to high temperatures (>85°C, 185°F), and
should be operated only within their defined operating specifications. Failure to adhere to operating specifications could result in poor device
performance or unsafe operating conditions. Exposure to the components contained within the ultracapacitor could be harmful under certain
circumstances. In case of exposure to ultracapacitor contents, wash affected area for at least 15 minutes with generous amounts of water and seek medical
attention. Fires involving these types of ultracapacitors should be extinguished with CO2, dry chemical, alcohol foam, or all purpose AFFF extinguishing
media. Water may be ineffective but should be used to cool fire-exposed containers, structures and to protect personnel.
BOOSTCAP® ultracapacitors are composed of the following major components:
Electrodes: Activated Carbon
Separator: Polypropylene or Cellulose
Electrolyte: Quaternary salt (tetraethylammonium tetraflouroborate)
Organic solvent (acetonitrile)
Other: Aluminum, steel
Disposal
BOOSTCAP ultracapacitors are neither specifically listed nor exempted from government hazardous waste regulations. The only material
of possible concern is the organic solvent, which when discarded or disposed of, is a hazardous waste according to Federal regulations (40
CFR 261). It is listed as Hazardous Waste Number U003, so listed due to its toxicity and ignitability. Disposal can occur only in properly
permitted facilities. Check state and local regulations for any additional requirements, as these may be more restrictive than federal laws
and regulations.
Transportation
Ultracapacitors as articles are not specifically listed nor exempted from hazardous materials regulations (HMR). The U.S. Department of
Transportation has provided Maxwell Technologies a written determination regarding Maxwell’s PC5 and PC10 BOOSTCAP
ultracapacitor products that the materials comprising the ultracapacitors are “…in a quantity and form that does not pose a hazard in
transportation. Therefore, the ultracapacitors are not subject to the HMR.”

Introduction 15
Perfect Pick User Manual - OPEX Corporation
Interlock system
The system interlocks include the drop-away panel (Figure 1), the light curtain
(shown in Figure 2), and the E-Stop switches. The light curtain is used to stop
just the iBOTs in the pick station area, should you have your hands in the iBOT
travel areas when the iBOTs are in motion.
Figure 1: Drop-away Panel (removed from the machine)
Note: The magnetic sensor is located at the bottom left side of the panel and
can be easily tripped by kicking the panel. When this panel is removed, all
iBOT motion will stop. This panel must be removed when the service
technician needs to install/remove an iBOT from the system.
Magnetic system interlock
WARNING: If an iBOT is completely discharged and away from the
charging rail, moving the iBOT so that it comes in contact with a live rail
could cause an arc capable of damaging the iBOT. Protections are in place
to prevent this from happening, but if the interlocks or e-stops are bypassed,
the potential for damage exists.

16 Introduction
Perfect Pick User Manual - OPEX Corporation
Emergency Stop (E-Stop) switches
The Perfect Pick system incorporates emergency-stop buttons and interlocks
to help keep the operator safe. Familiarize yourself with the location of the
machine Emergency Stop (E-stop) switches. The E-Stop should be used prior
to entering the machine, in the event of an emergency, or situations which may
result in personnel injury. The E-stops are installed on the front and back of the
machine. The big, red, mushroom-shaped emergency stop switches enable a
quick stop of all motors in the machine. If necessary, push one of the e-stops
and the machine will stop immediately and kill power to the charging rails. To
restart the machine, have the OPEX technician clear the machine (if needed),
pull the E-Stop knob out, and restart the machine by pressing the green Start
button. The Clear to Pick light is also a safety feature and only lights when it is
safe for the user to pick an item from the presented tote.
Figure 2: E-stop and interlock locations
E-Stop Switch
Light Curtain
Start button
Clear to Pick light

Introduction 17
Perfect Pick User Manual - OPEX Corporation
Light Tower
The light tower shows the status of the machine:
Blue - jammed/maintenance required
No Lights - Stopped/Off
Beeping Audible - Starting
Green - running normally
Red - Interlock/E-Stop tripped
Flashing Yellow - starting
Flashing Blue - maintenance mode (see note)
Note: From Maintenance mode, the machine is restarted which will
Once the technician determines that the machine is operating properly,
leaving only the solid green light.
bring the solid green light on in addition to the flashing blue light.
he/she will turn off the flashing blue light by exiting Maintenance mode,

18 Introduction
Perfect Pick User Manual - OPEX Corporation
Using Perfect Pick
Inventory Control System software
It is not the scope of this document to describe the functionality and operation
of the third-party Inventory Control System (ICS) software. However, it is
important to understand the basics, since the ICS provides the main interface
with the Perfect Pick system.
The inventory control software can operate in several modes. In normal
operations, the user will primarily use Continuous mode. This mode presents a
number of order-request containers to the picker along a conveyor, with each
container being replaced as soon as it is completed.
Another mode that may be used (depending on your setup) is Put-away mode,
which is used for restocking inventory. Put-away is initiated when an operator
selects put-away from the ICS user interface. The procedure is similar to
Continuous mode. A container with inventory items is presented to the
operator, who then puts the specified amount of items into the iBOT-delivered
tote.
Figure 3: Inventory Control System - example
Quantity
Item location
Item detail
Container detail Control buttons

Introduction 19
Perfect Pick User Manual - OPEX Corporation
Overview of operation (refer to Figure 3)
1 The monitor identifies the next item to be picked (Item detail), the Pick
Quantity, and the item location within the tote - an iBOT could present one
large tote, or a compartmentalized tote. Figure 3 (Item location) shows a
tote broken up into thirds, and the picker is directed to pick from the middle.
2 Pick the quantity identified in the interface (in this example, the quantity is
4). Depending on your operation, you might also have to bag the items and
place a label on the bag (the labeler is shown in Figure 5).
3 To the right of the Perfect Pick is a conveyor with containers. As the
containers advance toward the Perfect Pick, they pass a scanner (see
Figure 4), which reads the bar code on each container. The scanned
information is used to determine in which container to place the picked
parts.
Figure 4: Scanner
4 The monitor identifies the location of the container on the conveyor where
the user needs to place the picked part. There are four available locations
which are identified by the light bar (see Figure 5).
Scanner

20 Introduction
Perfect Pick User Manual - OPEX Corporation
Figure 5: Light bar
5 Put the selected quantity in the correct container(s).
6 Press the light bar button to advance to the next item.
7 When an order has been completed (all parts picked), a packing list is auto-
matically printed and the monitor displays a “Place document in container”
message (see Figure 6).
Note: Depending on your operation, your system may not require a printer.
In this example, 10 items are needed for the 3rd container,
and 30 items are needed for the 4th container.
Labeler Document printer
30 items
10 items